Food waste disposer throat baffle apparatus and method

ABSTRACT

Baffles for food waste disposers, systems employing such baffles, and methods of assembling, manufacturing, fabricating, or operating such baffles or baffle systems are disclosed herein. In one example embodiment, a baffle for implementation in connection with a food waste disposer includes a rim portion, a plurality of flaps, and a plurality of living hinges, wherein the rim portion, living hinges, and flaps constitute a single integrally-formed structure. The respective living hinges permit the respective flaps to be rotatable about respective axes that respectively are substantially tangent to respective locations along or proximate to the rim portion, so that the respective flaps can be rotated to respective closed positions. Either the living hinges or at least one additional component tend to cause the respective flaps to remain at the respective closed positions or to return to the respective closed positions when not at the respective closed positions.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 16/963,012, filed Jul. 17, 2020, and entitled “FOOD WASTEDISPOSER THROAT BAFFLE APPARATUS AND METHOD” the entire contents ofwhich are herein incorporated by reference.

FIELD

The present disclosure relates to waste disposers such as food wastedisposers and, more particularly, to baffles or splash guard componentsor features of such waste disposers, as well as methods of operating,assembling, manufacturing, fabricating, or implementing same.

BACKGROUND

In conventional food waste disposers, there is typically a baffle orsplash guard across the throat opening. For example, in some food wastedisposers, the throat baffle is inserted into the sink opening (strainerflange) and is removable by the user from the sink side. Also forexample, in some other food waste disposers, the baffle is integratedwith the mounting gasket and is only removable when the entire disposeris dismounted from the sink.

Depending upon the embodiment, the baffle of a food waste disposer canserve any of a variety of different purposes. For example, in at leastsome conventional embodiments, during disposer operation the baffleprevents splash back or particle ejection during grinding. Also forexample, the baffle in many or most (if not all) conventionalembodiments constitutes the primary user interface with the disposer, asthe food waste must pass through the baffle, usually assisted by theoperator, to enter the grind chamber. Further for example, the baffle,also in at least some conventional embodiments, prevents foreign objectssuch as silverware or sponges from entering the disposer both duringoperation and when not in use.

In at least some conventional embodiments, the baffle is made of nitrilerubber and has a pleated configuration. The pleats allow the baffleopening to enlarge as food waste is pushed through. The baffle howeveris also an obstacle to food waste entering the grind chamber. Moreparticularly, in at least some disposers, the pleats of the baffle arestiff enough to hold a layer of water over the baffle opening(s) duringthe operation of the disposer while permitting an adequate flow of waterfor grinding. Such a design results in water coverage over the openingsduring operation, which attenuates the noise from the grind chamber,because the throat opening is typically the dominant path for thetransmission of noise from the grind chamber to the user. One example ofa baffle that is used to reduce the noise transmission via the throatopening path is described in U.S. Pat. No. 7,264,188, which issued onSep. 4, 2007 and is entitled “Noise baffle for food waste disposer,” thecontents of which are hereby incorporated by reference herein.

Notwithstanding the effectiveness of certain conventional baffles inreducing noise during grinding, at least some such conventional bafflescan have undesirable side-effects. For example, the presence of thebaffles in sinks can result in the backing up of water into the sinks.In some cases, when water flows through a baffle into the grind chamberof a disposer, air inside the grind chamber is displaced and is ventedup out of the grind chamber back through the baffle. Although there canbe vent features or openings in the baffle that are intended tofacilitate the venting out of the displaced air from the disposer, insome circumstances the flowing water obstructs the vent openings beforethe displaced air has been vented, which prevents or restricts the airfrom leaving the grind chamber. Consequently, an air bubble can developunder the baffle, and the air bubble that is formed under the baffleprevents the water from draining through the baffle and causes water toback up into the strainer flange and into the sink. Such operation canappear to indicate a clogged sink problem to a user, and cause concernfor the user. Further, even though a user can readily remedy suchoperation by pushing down on the baffle pleats and displacing thetrapped air (which can be colloquially referred to as “burping thebaffle”), the user can find taking such action to be inconvenient ordistasteful.

Also for example, the presence of a conventional baffle can make itundesirably difficult to get food waste into the grinding chamber of adisposer. In some cases, to achieve the desired passing of food into thegrinding chamber, users will push food through the baffle with eithertheir hands or various utensils or devices. However, users again canfind taking such actions to be inconvenient or distasteful.Additionally, although other conventional baffles have pleats that mayquickly sag when the baffles are in use, so as to create larger centeropenings and diminish the resistance posed by the baffles to food wasteentering the disposers, food disposers employing such baffles can beviewed by some users as operating in a manner that is overly-aggressivein terms of the extent to which the disposers draw food into thegrinding chambers of the disposers. Additionally, the presence ofsagging baffles in some embodiments can also increase the probability offoreign objects entering the disposer.

In view of the above, it can be recognized that it is often desired thatthe throat baffles of disposers satisfy a variety of functionalobjectives substantially simultaneously. Indeed, it is often desiredthat a baffle operate to prevent material from leaving the grindchamber, that the baffle also allow appropriate material (food waste) toeasily enter the grind chamber, that the baffle further make it moredifficult for inappropriate material to enter the grind chamber, thatthe baffle attenuate noise, and that the baffle permit adequate waterflow for grinding. Further, it can be appreciated that simultaneouslysatisfying these various functional objectives of throat baffles ofdisposers by way of a single baffle can be challenging, particularlyinsofar as several of these functional objectives tend to be in conflictwith one another to a significant degree. As already discussed, althoughsome conventional baffles are capable of providing significant noiseattenuation, such conventional baffles can suffer from one or moreside-effects resulting from design features that are provided to achievesuch noise attenuation. Thus, with respect to at least some conventionalbaffles, users will complain that the baffles make it too difficult forfood to pass into the grinding chambers, and yet be pleased with thereduced noise levels associated with the disposers during grindingoperation.

Accordingly, it would be desirable if one or more improved baffles ordisposer systems employing baffles, or improved methods of baffle ordisposer system operation, assembly, manufacture, fabrication, orimplementation, could be developed that overcame one or more of theabove-described limitations associated with conventional baffles ordisposer systems, or that achieved one or more other objectives relatingto baffles or disposer systems employing baffles.

BRIEF SUMMARY

In at least some example embodiments, the present disclosure relates toa baffle for implementation in connection with a food waste disposer.The baffle includes a rim portion substantially circumferentiallyextending around a central axis of the baffle, and a plurality of flapsat least indirectly supported by the rim portion, where each of theflaps is substantially sector-shaped. Also, the baffle includes anannular portion connected or integrally formed with the rim portion,where the annular portion includes an outer surface configured tofacilitate mounting of the baffle in relation to an external structure.Further, each of the flaps is at least indirectly supported in relationto the rim portion in a rotatable manner such that each of the flaps canrotate about a respective additional axis that is substantially tangentto a respective location along or proximate to the rim portion.Additionally, each of the flaps can be rotated so as to attain arespective closed position in which the respective flap extends radiallyinwardly, from a respective radially-outward portion of the flappositioned proximate to the respective location to a respective tipportion of the flap. When each of the flaps is respectively rotated soas to attain the respective closed position, the respective tip portionsof the respective flaps collectively substantially define an innerorifice of the baffle through which the central axis passes. Further,the baffle includes one or more components that tend to cause therespective flaps to remain at the respective closed positions whenalready at the respective closed positions, and that tend to cause therespective flaps to return to the respective closed positions when notat the respective closed positions.

Additionally, in at least some example embodiments, the presentdisclosure relates to a baffle for implementation in connection with afood waste disposer. The baffle includes a rim portion substantiallycircumferentially extending around a central axis of the baffle, aplurality of flaps, and a plurality of living hinges, where therespective living hinges respectively link the respective flaps to therim portion such that the rim portion, living hinges, and flapsconstitute a single integrally-formed structure. Additionally, therespective living hinges permit the respective flaps to be rotatableabout respective axes that respectively are substantially tangent torespective locations along or proximate to the rim portion, so that therespective flaps can be rotated to respective closed positions. Eitherthe living hinges or at least one additional component tend to cause therespective flaps to remain at the respective closed positions whenalready at the respective closed positions, or to return to therespective closed positions when not at the respective closed positions.

Further, in at least some example embodiments, the present disclosurerelates to a method of assembling a baffle that is for implementation inconnection with a food waste disposer. The method includes providing aprimary structure having a first structural portion and a ringstructural portion, where the first structural portion includes a rimportion substantially circumferentially extending around a central axisof the baffle, a plurality of flaps, and a plurality of living hingesthat together constitute a single integrally-formed silicone structurethat is formed from a first material, and where the ring structuralportion is connected with or integrally formed with the first structuralportion. Additionally, the method includes overmolding a secondarystructure on the primary structure, where the secondary structure isformed from a second material, and where the secondary structureincludes a plurality of interlocking features that facilitate couplingof the secondary structure in relation to the primary structure. Eitherthe living hinges or at least one additional component tend to cause therespective flaps to remain at the respective closed positions whenalready at the respective closed positions, or to return to therespective closed positions when not at the respective closed positions.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of food waste disposer throat baffles and related methodsare disclosed with reference to the accompanying drawings and are forillustrative purposes only. The food waste disposer throat baffleapparatuses and methods encompassed herein are not limited in theirapplications to the details of construction, arrangements of components,or other aspects or features illustrated in the drawings, but rathersuch apparatuses and methods encompassed herein include otherembodiments or are capable of being practiced or carried out in othervarious ways. Like reference numerals are used to indicate likecomponents. In the drawings:

FIG. 1 is a bottom perspective view of a food waste disposer throatbaffle in accordance with a first embodiment encompassed herein;

FIG. 2 is a top perspective view of the baffle of FIG. 1 ;

FIG. 3 is an additional top perspective view of the baffle of FIG. 1 ,shown in combination with other portions of a food waste disposer ofwhich the baffle forms a part, as well as a strainer flange (typicallypart of a sink) in which the food waste disposer is mounted, shown incutaway;

FIG. 4 is a top perspective view of a combination of an annular manifoldand a flap that are components of the baffle of FIG. 1 ;

FIG. 5 provides an additional top perspective view of the flap of FIG. 4, shown apart from the annular manifold of FIG. 4 ;

FIG. 6 is an additional top perspective view of the combination of theannular manifold and the flap of FIG. 4 in which the flap is rotatedfurther downward relative to the annular manifold by comparison with theposition of the flap relative to the annular manifold in FIG. 4 ;

FIG. 7 is a further top perspective view of a combination of the annularmanifold and all of the flaps that are components of the baffle of FIG.1 ;

FIG. 8 is a bottom perspective view of an annular elastomer gasket incombination with the combination of the annular manifold and flaps ofFIG. 7 , all of which are components of the baffle of FIG. 1 ;

FIG. 9 shows a cutaway cross sectional view of a first portion of theannular manifold and an additional portion of the annular elastomergasket shown in FIG. 8 ;

FIG. 10 is a bottom perspective view of the components of the food wastedisposer throat baffle that are shown in FIG. 8 ;

FIG. 11 is a bottom perspective view of all of the components of thebaffle of FIG. 1 in which an elastic band component is in the process ofbeing assembled to (or disassembled from) the components of the baffleshown in FIG. 10 ;

FIG. 12 shows a cutaway bottom perspective view of a portion of thebaffle of FIG. 1 ;

FIG. 13 shows a cross sectional view of a portion of a food wastedisposer throat baffle differing from that of FIG. 1 , in accordancewith a second embodiment encompassed herein;

FIG. 14 shows a cross sectional view of a portion of a food wastedisposer throat baffle differing from that of FIG. 1 , in accordancewith a second embodiment encompassed herein;

FIG. 15 shows a top perspective view of a combination gasket that is acomponent of a fourth embodiment of food waste disposer throat bafflediffering from that of FIG. 1 and encompassed herein;

FIG. 16 shows a bottom perspective view of the combination gasket ofFIG. 15 ;

FIG. 17 is a bottom perspective view of the fourth embodiment of foodwaste disposer throat baffle of which the combination gasket of FIG. 15and FIG. 16 is a component;

FIG. 18 is a top perspective view of an additional food waste disposerthroat baffle in accordance with a fifth embodiment encompassed herein;

FIG. 19 is a top perspective view of a subassembly of components of thebaffle of FIG. 18 ;

FIG. 20 is a bottom perspective view of the subassembly of FIG. 18 ;

FIG. 21 is a bottom perspective view of the baffle of FIG. 18 ; and

FIG. 22 is a cutaway bottom perspective view of a gasket portion of thebaffle of FIG. 18 and FIG. 21 .

FIG. 23 is a bottom perspective view of a further food waste disposerthroat baffle in accordance with a sixth embodiment encompassed herein;

FIG. 24 is a bottom perspective view of a subassembly of components ofthe baffle of FIG. 23 ;

FIG. 25 is a perspective view of a cutaway portion of a cross-section ofthe baffle of FIG. 23 , taken when the baffle is in a non-invertedposition, where a flap of the baffle is shown to be in aslightly-depressed position relative to the positions of the flaps shownin FIG. 23 ;

FIG. 26 is an additional perspective view of an additional cutawayportion of an additional cross-section of the baffle of FIG. 23 , takenwhen the baffle is in an inverted position, and also when the flap ofthe baffle particularly shown in FIG. 26 takes on an elevated positionrelative to the positions of the flaps shown in FIG. 23 .

DETAILED DESCRIPTION

The present disclosure is intended to encompass any of a variety ofbaffles, food disposer systems employing such baffles, or methods ofbaffle or food waste disposer system operation, assembly, manufacture,fabrication, or implementation. In at least some such embodiments, thebaffles can be considered active baffles insofar as the baffles haveflaps (rather than pleats) and one or more components or features thattend to cause the flaps to maintain closed positions or return to closedpositions when not at closed positions. In at least some suchembodiments, the one or more components or features can include livinghinges by which the flaps are linked to an outer support portion of thebaffle such as a rim portion or support ring structural portion, suchthat the flaps, living hinges and outer support portion are integrallyformed. In at least some other embodiments, the one or more componentsor features can include an elastic band. Given such a configuration, theflaps tend to remain in closed positions so as to enhance soundreduction during food waste disposer system operation, but also stillpermit food waste to be inserted into the food waste disposer systemthrough the baffle with relative ease and permit appropriate levels ofwater passage through the baffle so as to diminish occurrences in whichit appears that a drain may be clogged. Indeed, with such aconfiguration, food waste can also fall into the food waste disposerthrough the baffle if the weight of that food waste is enough to causeone or more of the baffle flaps to open.

Referring to FIG. 1 , a bottom perspective view is provided of a firstbaffle system or simply baffle 100 that can be employed as part of (orin conjunction with) a food waste disposer or similar disposermechanism, in accordance with a first example embodiment encompassedherein. The bottom perspective view of the baffle 100 of FIG. 1 shows inrelative completeness most or substantially all of the component partsof the baffle. In particular, it can be appreciated from FIG. 1 that thebaffle 100 includes an annular manifold (or ring or rim portion) 102, aplurality of flaps 104 (in this example embodiment, eight of the flapsare present), an annular elastomer gasket 106, and an elastic band 108.

As will be described in further detail below, the flaps 104 are attachedat the base to circumferential features (e.g., at the annular manifold102), and the elastic band 108 serves to hold the flaps closed butallows them to open with slight pressure, making it easier to get foodwaste through the baffle. The annular manifold 102, flaps 104, annularelastomer gasket 106, and elastic band 108 can be made from any of avariety of materials depending upon the embodiment. In some exampleembodiments, the flaps 104 can be made from polypropylene or nylon, andthe annular manifold 102 can be made from nitrile rubber or athermoplastic elastomer (TPE). Also, the annular elastomer gasket 106and the elastic band 108 can be made from one or more of rubber, TPE,and/or one or more other elastomeric or flexible materials, dependingupon the embodiment.

As is evident from FIG. 1 , the flaps 104 are generally in the form ofsectors and extend from the annular manifold 102 radially inwardlytoward a central orifice 110 of the baffle 100. Further, each of theflaps 104 has a respective main flat surface portion 112 that extendsradially inwardly substantially from the annular manifold 102 to thecentral orifice 110, and each of the flaps additionally includes arespective tip portion 114 that extends along the inner orifice in adirection that approaches being perpendicular to the respective mainflat surface portion of the respective flap. As will be describedfurther below, each of the flaps 104 is capable of being rotateddownward or upward relative to the annular manifold 102 (when theannular manifold is oriented to be along a substantially horizontalplane), but FIG. 1 particularly shows all of the flaps in horizontal, orlargely-horizontal, positions. When positioned in this horizontal orlargely-horizontal manner as shown in FIG. 1 , the flaps 104 can be saidto be in their closed positions. It should be appreciated from FIG. 1that the central orifice 110 is substantially defined in its outerperimeter by the combination of the tip portions 114 of the flaps 104,particularly when the flaps 104 are in their closed positions. It shouldadditionally be appreciated from FIG. 1 that, although the closedpositions of the flaps 104 for simplicity are characterized above asbeing horizontal or largely-horizontal positions, in actuality the flaps104 even when in their closed positions do typically have a somewhatdownwardly-sloping profile—that is, each of the flaps 104 (and each ofthe main flat surface portions 112 thereof) does have some degree ofdownward slope as one proceeds radially inwardly from the annularmanifold 102 toward the central orifice 110. Further in this regard,because FIG. 1 is a bottom perspective view of the baffle 100 that showsthe baffle in a position that is substantially inverted relative to theposition it would have when normally installed in a food waste disposer,the sloping of the flaps 104 that is illustrated in FIG. 1 is theopposite of that described above—that is, the flaps 104 are illustratedin FIG. 1 to have some degree of upward slope as one proceeds radiallyinwardly from the annular manifold 102 toward the central orifice 110.

Referring additionally to FIG. 2 , a top perspective view of the baffle100 is provided to supplement the view provided in FIG. 1 . In contrastto the view provided by FIG. 1 , the top perspective view of FIG. 2 doesnot allow for all of the components of the baffle 100 to be visible.More particularly, FIG. 2 specifically reveals only the flaps 104leading up to the central orifice 110 of the baffle 100, as well as theannular elastomer gasket 106.

Referring additionally to FIG. 3 , a further top perspective view of thebaffle 100 is provided in which the baffle is shown to be implemented aspart of a food waste disposer and a portion of a sink with respect towhich the food waste disposer is mounted. More particularly in thisregard, FIG. 3 illustrates a top perspective view of a combinationsystem 300 that includes a strainer flange 302 and portions 304 of afood waste disposer 306, in addition to the baffle 100. It should beappreciated that the baffle 100 and the portions 304 can all beconsidered to be encompassed by the food waste disposer 306.Additionally, in some embodiments the strainer flange 302 can also beconsidered to be encompassed by the food waste disposer 306—for example,the strainer flange 302 can be considered to be another portion of thefood waste disposer 306 in addition to the portions 304. Further forexample in this regard, the strainer flange 302 can be a part of a foodwaste disposer mounting assembly that is installed in the sink andretained in position by other components of the disposer mountingassembly. However, in other embodiments the strainer flange 302 can beconsidered to be part of (e.g., an integral part of) a sink that isdistinct from the food waste disposer. For purposes of the presentdisclosure, therefore, the illustration of the strainer flange 302 inFIG. 3 relative to the portions 304 can be understood to berepresentative of the presence of a sink in relation to a food wastedisposer.

The view provided by FIG. 3 is a view that is largely consistent withthe view that a user of the food waste disposer 306 would have of thefood waste disposer and the baffle 100 thereof when using the food wastedisposer. At the same time, it should also be appreciated that theportions 304 of the food waste disposer 306 that are visible in FIG. 3(not including the baffle 100 itself) are those portions of the foodwaste disposer that are typically beneath the baffle 100, including theportions that define the grinding chamber of the food waste disposer.Given that the baffle 100 typically is mounted at or proximate to thebottom level of a sink in relation to which the food waste disposer 306is mounted, the portions 304 of the food waste disposer 306 aretypically beneath the sink, and consequently (notwithstanding what isshown in FIG. 3 ) the portions 304 of the food waste disposer 306 arenot typically visible during normal use of the food waste disposer.

It will be appreciated that the combination system 300 during operationof the food waste disposer 306 involves directing food waste or otherwaste downward toward and through the central orifice 110 generally in adirection indicated by an arrow 308. The arrow 308 can be understood tobe (or correspond to) a central axis of the baffle 100 that isperpendicular to a plane defined by the annular manifold 102 shown inFIG. 1 , as well as perpendicular to a plane defined by an upper annularlip 310 of the annular elastomer gasket 106. It should further beapparent from a comparison of FIG. 1 and FIG. 3 that the tip portions114 of the baffle 100 generally extend in directions that are parallelto the direction of the arrow 308. Also, it should be appreciated from acomparison of FIG. 1 and FIG. 3 that, to the extent that the flaps 104have a downward sloping profile even when in their closed (or horizontalor largely-horizontal) positions as described above, the downward slopeof each of the flaps 104 is in the direction of the arrow 308 (that is,downward into the food waste disposer 306) as one proceeds radiallyinwardly from the annular manifold 102 toward the central orifice 110.

Turning now to FIG. 4 , FIG. 5 , FIG. 6 , FIG. 7 , FIG. 8 , FIG. 9 ,FIG. 10 , FIG. 11 , and FIG. 12 , various components and groupings ofthe components of the baffle 100 are shown in more detail, to illustrateadditional features of those components, as well as to illustrate aprocess of assembly of the baffle 100. First, FIG. 4 , FIG. 6 , and FIG.7 are provided to illustrate a first step of assembly of the baffle 100in which the flaps 104 are assembled to the annular manifold 102. FIG. 5additionally provides a perspective view of a first one 400 of the flaps104, including features that allow for the flap to be coupled to theannular manifold 102. In the present embodiment, each of the features ofthe first one 400 of the flaps 104 of FIG. 5 is also present in each ofthe other flaps 104 of the baffle 100, albeit in other embodimentsdifferent ones of flaps can have different features relative to oneanother. Further, FIG. 8 , FIG. 9 , FIG. 10 , and FIG. 11 illustrateother steps of the process of assembly of the baffle 100, or features ofthe baffle 100 or components thereof that facilitate the assemblyprocess.

Referring to FIG. 5 , as represented by the first one 400 of the flaps104 shown therein, each of the flaps 104 includes several features ofnote. First, each of the flaps 104 includes a respective extensionportion 502 that is formed as a respective integral extension of arespective outer diameter edge 504 of that flap. Additionally, each ofthe extension portions 502 of the respective flaps 104 (including theextension portion of the first one 400 of the flaps shown in FIG. 5 )includes a respective pair of integrated pins 506. The two respectivepins of each of the respective pairs of integrated pins 506 of therespective flaps 104 (including the first one 400 of the flaps shown inFIG. 5 ) generally extend in directions opposite from one another alonga respective axis that is parallel to a respective tangent line definedby the respective outer diameter edge 504 of the respective flap.

Additionally as illustrated by FIG. 5 , each of the flaps 104 alsoincludes a respective curved transition region 508 that links therespective tip portion 114 of the respective flap with the respectivemain flat surface portion 112 of the respective flap. Further, each ofthe flaps 104 has a respective first side edge 510 and a respectivesecond side edge 512, both of which extend from the respective outerdiameter edge 504 to the respective tip portion 114 of the respectiveflap (along the opposite sides of the respective flap). In the presentembodiment, each of the first and second side edges 510, 512 of each ofthe flaps 104 is generally rounded or curved. Additionally, each of thetip portions 114 of the respective flaps 104 is elongated. Although thelengths of the tip portions of the flaps can vary depending upon theembodiment, in the present embodiment the length of each of the tipportions 114 can be, for example, up to 3 millimeters. Given the shapeof the tip portions 114 of the flaps 104, when the flaps 104 are intheir horizontal or largely-horizontal positions as shown in FIG. 1 ,the tip portions 114 generally extend in the direction of the arrow 308shown in FIG. 3 (and FIG. 8 ).

Referring now to FIG. 4 , it should be appreciated that the respectiveintegrated pins 506 of the respective flaps 104 as shown in FIG. 5 allowfor the respective flaps to be assembled to the annular member 102. Moreparticularly, FIG. 4 shows that the annular manifold 102 includesmultiple (in this example, eight) pairs of slots 402. Further, basedupon a comparison of FIG. 5 with FIG. 4 , it will be understood that therespective pins of the pair of integrated pins 506 of the first one 400of the flaps 104 can be press fit into the respective slots of any ofthe pairs of slots 402 of the annular manifold 102. The integrated pins506 (of the pair of integrated pins) particularly enter thecorresponding slots 402 by proceeding downward through a top surface 404of the annular manifold 102 and into the slots. Likewise, it should beappreciated that the respective integrated pins of each of the otherpairs of integrated pins 506 of the other ones of the flaps 104 can bepress fit into the respective slots of respective other ones of thepairs of slots 402 of the annular manifold 102. That is, the process ofassembling each and every one of the flaps 104 onto the annular manifold102 involves press fitting the respective pins of the respective pair ofintegrated pins 506 of the respective flap into counterpart ones of arespective pair of slots 402 on the annular manifold 102.

FIG. 4 particularly shows the first one 400 of the flaps as extendingradially inwardly toward the center of the annular manifold 102, in amanner such that the flap extends in a manner that is largely within orparallel to a plane defined by the annular manifold 102. However, itshould be understood that in the present embodiment the integrated pins506 of each of the flaps 104 such as the first one 400 of the flaps areconfigured to fit loosely within the counterpart ones of the slots 402of the annular manifold 102. Consequently, assuming that the planedefined by the annular manifold 102 is substantiallyhorizontally-orientated, after the integrated pins 506 of the first one400 of the flaps 104 are press fit into the counterpart ones of theslots 402 of the annular manifold 102, the flap will tend to hang downvertically due to gravity acting upon the flap, as illustrated by FIG. 6.

Further, referring to FIG. 7 , upon the assembly of all of the flaps 104(in this example, all eight flaps) so that the respective integratedpins 506 of each respective flap are pressed fit into the respectiveslots 402 of the annular manifold 102, then an overall subassembly 700including the annular manifold and all of the flaps is achieved as shownin FIG. 7 . In the present embodiment, consistent with the descriptionprovided regarding FIG. 6 , the integrated pins 506 of each of the flaps104 are configured to loosely fit within the slots 402 and consequently(assuming that the annular manifold 102 is positioned so that a planedefined thereby is horizontal relative to the ground) all of the flaps104 are shown to hang loosely downward in FIG. 7 .

Therefore, in view of FIG. 4 , FIG. 5 , FIG. 6 , and FIG. 7 , it shouldbe appreciated that the first step of assembly of the baffle 100involves repeatedly press fitting each of the flaps 104 onto the annularmanifold 102 so that all of the flaps 104 are supported by the annularmanifold. Further, due to the interaction between the integrated pins506 and the slots 402, this step of assembly results in the subassembly700 in which the respective flaps can be easily rotated relative to theannular member. Each of the respective flaps 104 particularly isrotatable about a respective axis that is determined by the interactionof the respective integrated pins 506 of the respective flap with thecounterpart ones of the slots 402 of the annular manifold 102 into whichthose respective pins have been situated (e.g., where the respectiveaxis coincides with a respective center axis of the respective pair ofintegrated pins), where the respective axis is parallel to a respectivetangent line defined by the respective outer diameter edge 504 of therespective flap (as discussed above in regard to FIG. 4 and FIG. 5 ).

Turning to FIG. 8 , FIG. 9 , and FIG. 10 , a second step of assembly ofthe baffle 100 involves assembling the annular elastomer gasket 106around and in relation to the subassembly 700 of FIG. 7 . FIG. 8particularly provides a bottom perspective view of the annular elastomergasket 106 after it has been placed around and in relation to thesubassembly 700 including the annular manifold 102 and the flaps 104,with the flaps all extending downward in the same manner as shown inFIG. 7 . FIG. 8 therefore shows a further subassembly 800 including allof those components, that is, all of the annular elastomer gasket 106,the annular manifold 102, and all of the flaps 104. The manner in whichan elastomer gasket, such as the annular elastomer gasket 106, can beassembled to another structure such as the subassembly 700 can varydepending upon the embodiment, and one example manner of assembly isdescribed further below.

More particularly, in the present embodiment, it will be appreciatedfrom FIG. 4 as well as FIG. 8 that the annular manifold 102 includes aplurality of (in this example, eight) elliptical holes 802 that arespaced equidistantly around the circumference of the annular manifold,where the respective elliptical holes are positioned between respectivepairs of neighboring ones of the slots 402, respectively. Each of theelliptical holes 802 extends through the annular manifold 102 from thetop surface 404 (see FIG. 4 ) of the annular manifold to a bottomsurface 801 of the annular manifold (see FIG. 8 ). Correspondingly, theannular elastomer gasket 106 includes a plurality of (in this example,also eight) elastomer (for example, rubber) protrusions or spigots 804that are spaced around the circumference of a bottom annular surface 806of the annular elastomer gasket 106 that interfaces the top surface 404(see FIG. 4 ) of the annular manifold 102 when the annular elastomergasket is assembled to the annular manifold.

Given the presence of the elliptical holes 802 and the spigots 804, theannular elastomer gasket 106 more particularly is assembled in relationto the annular manifold 102 by aligning the spigots 804 of the annularelastomer gasket in relation to the elliptical holes 802 of the annularmanifold 102 and then pressing the annular elastomer gasket 106 towardthe annular manifold 102 so that the bottom annular surface 806 of theannular elastomer gasket interfaces the top surface 404 (see FIG. 4 ) ofthe annular manifold. In FIG. 8 , the annular elastomer gasket 106particularly is pressed in relation to the annular manifold 102 in thedirection represented by the arrow 308 (as also shown in FIG. 3 ) sothat the respective spigots 804 enter into and pass through therespective elliptical holes 802. Given that the annular elastomer gasket106 is malleable to some degree, this process typically involvespressing the annular elastomer gasket relative to the annular manifold102 locally, at or near each of the spigots 804, so that each one of thespigots is pressed into and through a corresponding one of theelliptical holes 802.

Referring additionally to FIG. 9 , a cutaway cross sectional view isprovided of a first portion of the annular manifold 102 and anadditional portion of the annular elastomer gasket 106 to illustrate inmore detail the manner in which the annular elastomer gasket 106 isassembled in relation to the annular manifold 102 by way of the spigots804 and the elliptical holes 802. More particularly, it will beappreciated that FIG. 9 shows a cross section of a first one 904 of thespigots 804 that is positioned within a first one 902 of the ellipticalholes 802. As shown further, the first one 904 of the spigots 804 has,as does each of the other spigots 804, a tip portion 906 that is largerin diameter than a neck portion 908 extending between the tip portionand a main annular body 910 of the annular elastomer gasket 106. Thediameter of the neck portion 908 is generally about the same size as thenarrowest diameter of the elliptical holes 802, and the diameter of thetip portion 906 is larger than the narrowest diameter of the ellipticalholes.

Consequently, although the malleability of the annular elastomer gasket106 allows for the spigots 804, such as the first one 904, to passthrough the elliptical holes 802, such as the first one 902, once a tipportion of a spigot, such as the tip portion 906 of the first one 904has passed through a respective elliptical hole such as the first one902, then that spigot tends to be substantially locked into positionrelative to the annular manifold 102. Thus, with all of the spigots 804positioned respectively through all of the corresponding ellipticalholes 802, respectively, there is strong resistance to disassembly ofthe annular elastomer gasket 106 from the annular manifold 102, albeitstrong efforts to pull the annular elastomer gasket 106 away from theannular manifold 102 will result in such disassembly.

In addition to these features shown in FIG. 9 , it should also bepointed out that, as illustrated therein, the annular elastomer gasket106 includes an outer perimeter wall 912. As shown, when the annularelastomer gasket 106 is assembled to the annular manifold 102, the outerperimeter wall 912 overhangs and extends around an outer circumferentialperimeter 914 of the annular manifold 102. Also, the annular elastomergasket 106 further includes inner lip portions 916 (see also FIG. 8 )that extend around and past an inwardly-facing edge of the annularmanifold 102 so as to extend around and apply pressure upon the annularmanifold at both the top surface 404 and the bottom surface 801 of theannular manifold. Therefore, the interactions between the inner lipportions 916 and the annular manifold 102 supplement the interactionsbetween the spigots 804 and elliptical holes 802 in terms of attachingthe annular elastomer gasket 106 to the annular manifold 102.

It is envisioned, with respect to the assembly of the flaps 104 inrelation to the annular manifold 102 and additionally with respect tothe assembly of the annular elastomer gasket 106 to the subassembly 700(including the flaps 104 and annular manifold 102), that these assemblysteps can be performed easily with these components being positionedsubstantially in a “right-side up” manner. That is, as described above,during the performing of these steps, the annular manifold 102 ispositioned horizontally so that the top surface 404 faces upward. Withsuch positioning of the annular manifold 102, the slots 402 arepositioned to receive the integrated pins 506 by pressing the integratedpins downward into the slots 402, and the annular elastomer gasket 106is attached to the annular manifold 102 by pressing the annularelastomer gasket down onto the top surface 404 of the annular manifold102. With assembly in this manner, the flaps 104 tend to take a hangingposture relative to the annular manifold 102 and the annular elastomergasket 106, as shown in FIG. 7 and FIG. 8 .

Nevertheless, to complete assembly of the baffle 100, as shown in FIG.10 , it is most convenient at this juncture in the assembly process toinvert the further subassembly 800 of FIG. 8 so that all of the flaps104 revert to a closed status, that is, such that all of the flaps nolonger hang downward but rather have become repositioned so that all ofthe tip portions 114 of the flaps 104 approach one another so as todefine the central orifice 110. As illustrated, when the flaps 104 arepositioned in this manner, the main flat surface portions 112 of theflaps generally extend radially inward toward the central orifice 110,in a largely (but not strictly) horizontal manner. More particularly,when the further subassembly 800 is inverted as shown in FIG. 8 , themain flat surface portions 112 extend largely horizontally but also havea slight incline as those portions extend radially inwardly toward thecentral orifice 110. Correspondingly, if the further subassembly 800 waspositioned right-side-up, the main flat surface portions 112, whenpositioned relative to the remainder of the further subassembly 800 asshown in FIG. 10 , would have a slight decline as those portionsextended radially inwardly toward the central orifice 110.

With the flaps 104 positioned as shown in FIG. 10 , then the elasticband 108 can be positioned in relation to the further subassembly 800 asillustrated by FIG. 11 . More particularly, the elastic band 108 isassembled to the further subassembly 800 by placing the band underrespective retaining ribs 1102 of the respective flaps 104. In FIG. 11 ,the elastic band 108 is displayed as being first positioned under onlyone (e.g., a first one) of the retaining ribs 1102. Nevertheless, itshould be appreciated that, to complete the assembly of the elastic band108 in relation to the further subassembly 800 and arrive at the baffle100 of FIG. 1 , the elastic band then additionally is placed under eachand every other one of the (in this example, each and every one of theremaining seven) retaining ribs 1102 associated with each of theremaining ones of the flaps 104. Although the elastic band can beimplemented by hand, the elastic band can also be positioned using atoothpick or other tool. It is recommended to avoid twists in theelastic band when implementing the elastic band.

Further with respect to the assembly of the elastic band 108 onto thefurther subassembly 800, FIG. 12 shows a cutaway perspective view of aportion of the baffle 100 after the elastic band has been fullyimplemented as part of the baffle. FIG. 12 particularly illustrates howthe retaining rib 1102 of the first one 400 of the flaps 104 takes theform of a triangularly-shaped protrusion that extends radially outwardfrom the outer diameter edge 504 of that flap and that includes asupport surface 1200. It will be appreciated that all of the otherretaining ribs 1102 of the others of the flaps 104 not shown in FIG. 12also take this form. Accordingly, when the baffle 100 is positioned inthe right-side up manner such that the top surface 404 of the annularmanifold 102 faces upward, the elastic band 108 rests upon all of thesupport surfaces 1200 of the retaining ribs 1102 of the flaps 104 and ispositioned in between those support surfaces 1200 and the annularmanifold 102.

Once the step of assembling the elastic band 108 onto the furthersubassembly 800 is completed, the process of assembling the baffle 100is completed. With the baffle 100 in this completed state, the elasticband 108 extends generally along the entire circumference of the annularmanifold 102 and around all of the retaining ribs 1102 of all of theflaps 104. In this position, the elastic band 108 tends to provide aradially-inwardly-directed compressive force upon all of the outerdiameter edges 504 of all of the flaps 104 tending to cause all of theflaps to take on their positions relative to the annular manifold 102 asshown in FIG. 1 . That is, the elastic band 108 tends to cause all ofthe flaps 104 to take on their horizontal or largely-horizontal (andradially-inwardly-extending), or closed, positions such that the tipportions 114 of the flaps substantially define the central orifice 110.Further, when the baffle 100 is positioned right-side-up (opposite tothe position shown in FIG. 1 ), the elastic band 108 provides a returnforce upon all of the flaps 104 that tends to bring all of the flaps totheir closed positions, rather than allowing any of the flaps to remainin a hanging position as shown in FIG. 7 /FIG. 8 .

Baffles having features that are in accordance with, or substantially orlargely in accordance with, the baffle 100 described above in regard toFIG. 1 through FIG. 12 may, depending upon the exact embodiment exhibitone or more advantages by comparison with one or more conventionalbaffles. For example, the baffle 100 is designed so that it can fit intoa strainer flange such as the strainer flange 302 of FIG. 3 in a mannerthat is identical to or similar to the manner in which at least someconventional baffles engage a strainer flange. Thus, the baffle 100would be removable from a sink opening to leave the full drain openingaccessible to a user for cleaning purposes or to allow for the clearingof jammed material from the grind chamber of a food waste disposer, suchas the food waste disposer 306.

Further for example, as described above, the flaps 104 of the baffle canbe made from a material such as polypropylene or nylon that is rigid bycomparison with some other materials that are used for flaps in one ormore conventional baffles. Additionally, given the shape of the flaps104 that include the elongated tip portions 114, it is easier for a userwho has inserted the user's hand or fingers through the central orifice110 (e.g., to push food material through the central orifice 110 intothe food waste disposer 306) to subsequently remove the user's hand orfingers from the central orifice 110 and away from the food wastedisposer 306 than is the case with one or more conventional baffles.That is, in the case of one or more conventional baffles that have flaps(rather than pleated configurations), as a user withdraws the user'shand from the baffle, the flap tips tend to trap or pinch on the user'shand making it difficult to withdraw the hand. By comparison, the baffle100 can be viewed as a baffle design that may minimize or reducefinger-trapping that can occur.

Additionally for example, although one or more conventional bafflesemployed with food waste disposers are molded as a single part, thebaffle 100 is not molded as a single part—instead, the baffle 100 hasthe flaps 104 that are distinct from and are assembled to the annularmanifold 102, and additionally has the elastic band 108 that isassembled around the flaps 104 (also, the annular elastomer gasket 106is assembled to the annular manifold). Given that the annular manifold102, the flaps 104, and the elastic band 108 are distinct components,the stiffness (or elasticity) of the elastic band may be set or selectedin a manner that takes into account or balances characteristics ofinterest of the flaps. Further for example in this regard, the stiffnessof the elastic band 108 may be set or selected to balance the resistanceof the flaps 104 to water flow with the ease of food waste passingthrough the baffle 100.

Because the baffle 100 employs the elastic band 108, which tends to movethe flaps 104 to their horizontal or largely-horizontal (or closed)positions, the baffle may be considered an active baffle design, ratherthan a passive baffle design. As an active baffle design, the baffle 100also may provide any of a variety of further advantages (e.g., inaddition to or instead of any of those mentioned above) by comparisonwith one or more conventional passive baffle designs including, furtherfor example, enhanced sound reduction, increased ease of food wasteinsertion, and improved, appropriate, water draining, regardless of thewater flow characteristics of the installation.

Additionally, although it is possible for all of the flaps 104 of thebaffle 100 to move in unison, it is also possible for any of the flapsto move individually, or for two or more of the flaps to move while oneor more others of the flaps do not move, or for different one(s) of theflaps to move to different degrees than other one(s) of the flaps. Thisis to be contrasted with one or more conventional pleated baffledesigns. In such conventional baffles, the pleats of the baffle all areinterconnected and move together, such that the combined stiffness ofall of the pleats may be too high for the pleats to be displaced andallow water to flow through the baffle properly under certain water flowconditions. By comparison, the baffle 100 may operate in a manner suchthat, in some operational circumstances, only a subset of the flaps 104(e.g., as few as one or two of the flaps 104) is or are displaced inresponse to water flow, while the remaining ones of the flaps is or arenot displaced, thereby facilitating water flow.

Notwithstanding the description provided above regarding the elasticband 108, in other embodiments other components or features can beemployed to apply pressure tending to return the flaps 104 to ahorizontal position. FIG. 13 and FIG. 14 particularly show cutaway crosssectional views of two alternate embodiments of the baffle 100, namely,a first alternate baffle 1300 and a second alternate baffle 1400, inwhich an elastic band is absent and instead other mechanisms areemployed to cause the flaps of the baffles to return to a horizontalstate.

Particularly with regard to the embodiment of FIG. 13 , the firstalternate baffle 1300 includes an annular manifold 1302, a plurality offlaps 1304 (one of which is shown), and an annular elastomer gasket1306, which respectively correspond to the annular manifold 102, theflaps 104, and the annular elastomer gasket 106, respectively, of thebaffle 100. However, in the embodiment of FIG. 13 , rather thanemploying an elastic band corresponding to the elastic band 108, insteadeach of the flaps 1304 is rotatably coupled to the annular manifold 1302by way of a respective rotation pin 1308 (one of which is shown in FIG.13 ). In addition, respective torsion springs 1307 (again one of whichis shown in FIG. 13 ) are respectively positioned around the respectiverotation pins 1308 associated with the respective flaps 1304, and arerespectively fixed in place by way of respective machine screws 1310.The respective torsion springs 1307 are configured, relative to therespective flaps 1304, so that the respective torsion springs tend to bedeformed when the respective flaps begin to sag or rotate downward.Thus, the respective torsion springs 1307 tend to force the respectiveflaps 1304 to return to a horizontal or largely-horizontal (or closed)state when the respective flaps sag or rotate downward.

As for the embodiment of FIG. 14 , the second alternate baffle 1400 alsoincludes a plurality of flaps 1404 (one of which is shown), and anannular elastomer gasket 1406, which respectively correspond to theflaps 104 and the annular elastomer gasket 106, respectively, of thebaffle 100. In contrast with the embodiment of FIG. 13 , in theembodiment of FIG. 14 there is no distinct annular manifold but ratherall of the flaps 1404 are directly hinged relative to the annularelastomer gasket 1406 itself. Further, instead of utilizing the elasticband 108 or torsion springs 1307, it is the annular elastomer gasket1406 itself that provides the force that tends to cause the flaps 1404to return to their closed state.

In order to achieve such operation, each of the flaps 1404 includes arespective slot 1408 (one of which is shown in FIG. 14 ), andadditionally the annular elastomer gasket 1406 includes a plurality ofelastomer (e.g., rubber or TPE) fingers or flaps 1410 (one of which isshown in FIG. 14 ), where the number of the elastomer fingers 1410equals the number of the slots 1408. As illustrated by FIG. 14 , whichshows one of the elastomer fingers 1410 extending into one of the slots1408, the respective elastomer fingers 1410 respectively extend into therespective slots 1408 when the respective flaps 1404 are assembled tothe annular elastomer gasket 1406. Given this arrangement, when therespective flaps 1404 sag or hang downward, the respective elastomerfingers 1410 become bent or distended and tend to provide a restoringforce causing the respective flaps 1404 to return to a horizontal orlargely-horizontal (or closed) state. Thus, the elastomer fingers (orflaps) 1410 of FIG. 14 act as springs and can be referred to as livingsprings or elastomeric hinges.

Turning to FIG. 15 , FIG. 16 , and FIG. 17 in a further alternate baffleembodiment differing from the baffle 100, it is possible to integrateaspects of the annular manifold 102, the flaps 104, and the annularelastomer gasket 106 into a single combination gasket 1500 as shown. Insuch an embodiment, the combination gasket 1500 includes flap portions1504 that are integral extensions of an annular elastomer gasket portion1506. A lower rim portion 1502 of the annular elastomer gasket portion1506 from which the flap portions 1504 extend, can be consideredanalogous to the annular manifold 102. Because the flap portions 1504and the annular elastomer gasket portion 1506 (including the lower rimportion 1502) are integrally formed with one another, the combinationgasket 1500 can be molded out of a single material and thus can avoidcomplications associated with the assembly of multiple components suchas the annular manifold 102, the flaps 104, and the annular elastomergasket 106. The combination gasket 1500 can be molded in a flap down,open configuration, as shown in FIG. 15 although, in other embodiments,the flap portions 1504 can be molded to extend in other directions.

In addition to FIG. 15 , which shows a top perspective view of thecombination gasket 1500, FIG. 16 also provides an additional bottomperspective view of the combination gasket 1500. FIG. 16 particularlyillustrates how, in this embodiment, underside surfaces 1510 of the flapportions 1504 have several features, namely, center ribs 1512 and edgestiffeners 1514. The edge stiffeners 1514 respectively take the form ofbent, downwardly-extending flanges of the respective flap portions 1504that extend radially-inwardly along substantially the entire lengths ofthe respective side edges of the respective flap portions, up to andaround respective tip portions 1516 of the respective flap portions. Thecenter ribs 1512 respectively are ridges that extend from the respectivetip portions 1516 of the respective flap portions 1504radially-outwardly toward the lower rim portion 1502, along respectiveradially-extending midlines of the respective flap portions. Prior toreaching the lower rim portion 1502, the center ribs 1512 respectivelyterminate at respective T-shaped ends 1518.

Referring additionally to FIG. 17 , the combination gasket 1500 of FIG.15 and FIG. 16 can be implemented as a baffle 1700 upon the addition ofan elastic (for example, rubber or TPE) band 1508 to the combinationgasket. As shown by FIG. 17 , which particularly provides a bottomperspective view of the baffle 1700, the elastic band 1508 whenimplemented on the combination gasket 1500 extends around the T-shapedends 1518. By virtue of this arrangement, the elastic band 1508 appliespressure to each of the T-shaped ends 1518 and thereby to each of theflap portions 1504, which tends to move the respective flap portions tohorizontal or largely-horizontal (or closed) positions from the moldedopen positions shown in FIG. 15 and FIG. 16 . That is, a purpose of thecenter ribs 1512 is to translate the elastic (e.g., rubber) band springforce toward the center of the baffle 1700 and to force the flapportions 1504 into a closed position from the molded open position or,in other words, the elastic band 1508 exerts a spring force on the flapportions 1504 tending to close the flap portions.

Referring next to FIG. 18 , a top perspective view of an additionalexample baffle 1800 encompassed herein is shown. As described further inrelation to FIG. 19 , FIG. 20 , FIG. 21 and FIG. 22 , the baffle 1800includes a substrate 1802 with multiple flaps 1804 and additionally acylindrical gasket 1806. As was the case with the baffle 100, the baffle1800 can form part of a food waste disposer as described above in regardto the baffle 100 and the food waste disposer 306. Also, the baffle 1800can be implemented in regard to a strainer flange of a sink such as thestrainer flange 302. In particular, as was the case with the annularelastomer gasket 106 of the baffle 100 described above, the cylindricalgasket 1806 is configured to allow for positioning of the baffle 1800within a strainer flange in a sink, in the same or substantially thesame manner as is shown in FIG. 3 regarding implementation of the baffle100 in the strainer flange 302.

Turning particularly to FIG. 19 and FIG. 20 , additional top perspectiveand bottom perspective views are provided, respectively, of asubassembly 1900 that is included as part of the baffle 1800. Thesubassembly 1900 particularly includes the substrate (or substratecomponent) 1802 with the flaps 1804 mentioned above in regard to FIG. 18. Further as shown, the substrate 1802 includes an outer rim portion1902 that surrounds all of the flaps 1804. Each of the flaps 1804 isconnected to the outer rim portion 1902 by way of a respective livinghinge 1904 extending outward from a respective radially-outward portion2004 of the respective flap. In the present embodiment, each livinghinge 1904 is essentially a narrow neck portion of the same material outof which each of the outer rim portion 1902 and the flaps 1804 areformed, and all of the outer rim portion 1902, the flaps 1804, and theliving hinges 1904 linking the flaps with the outer rim portion 1902 areintegrally formed as a single structure. In the present exampleembodiment, the substrate 1802 in its entirety, including outer rimportion 1902, the flaps 1804, and the living hinges 1904, can be madeusing silicone, which provides a tactile rubbery feel to the flaps 1804and provides an appropriate level of robustness for the living hinges1904.

Each living hinge 1904 serves to allow the respective flap 1804associated with that living hinge to rotate upward and downward relativeto the outer rim portion 1902 in substantially the same manner as eachof the flaps 104 can rotate relative to the annular manifold 102 of thebaffle 100 described above. More particularly, each of the flaps 1804can be rotated relative to the outer rim portion 1902, as permitted bythe respective one of the living hinges 1904, above or below ahorizontal or largely horizontal (or closed) position in which therespective flap 1804 extends generally or substantiallyradially-inwardly toward a center of the outer rim portion 1902. Inaddition to permitting such rotation of the flaps 1804, the livinghinges 1904 can also serve, during assembly or manufacture of the baffle1800, as runners in the molding process, so as to allow for the moldingof the flaps 1804 and the outer rim portion 1902 as one part.

It should be appreciated from FIGS. 19 and 20 that the flaps 1804 of thebaffle 1800 can have features that are identical or substantiallyidentical to those shown in FIG. 5 regarding the first one 400 of theflaps 104, except insofar as the flaps 1804 have the living hinges 1904extending from the radially-outward portions 2004 of the flaps ratherthan the extension portions 502 (or pair of integrated pins 506). Inparticular, each of the flaps 1804 includes a respective tip portion1814 that is elongated in the same manner as the tip portions 114. Asshown in FIGS. 18, 19 and 20 , when the flaps 1804 are all in thehorizontal or largely-horizontal (or closed) positions, the tip portions1814 of the flaps collectively define (or substantially define) an innerorifice 1810 of the baffle 1800.

Further, each of the flaps 1804 includes a respective main flat surfaceportion extending from the respective radially-outward portion 2004 ofthe respective flap toward the respective tip portions 114 of the flap,as well as a respective curved transition region linking the respectivemain flat surface portion with the respective tip portion. The main flatsurface portions and curved transition regions of the flaps 1804correspond to the main flat surface portions 112 and curved transitionregions 508 of the flaps 104 described above. Additionally, each of theflaps 1804 also includes respective first and second side edges that aregenerally rounded or curved and that respectively correspond to thefirst and second side edges 510, 512 described above in regards to theflaps 104 of the baffle 100.

As is evident particularly from FIG. 20 (as well as partly from FIG. 19), the subassembly 1900 not only includes the substrate 1802 with theflaps 1804, but also includes a support ring 2000. The outer rim portion1902 of the substrate 1802, in addition to extending entirely around allof the flaps 1804, also includes multiple (in this example, eight)circumferentially-extending channel segments 2002 through which thesupport ring 2000 passes. By virtue of the support ring 2000 passingthrough the circumferentially-extending channel segments 2002, thesupport ring is held in position relative to the substrate 1802 andtherefore can provide support to the substrate so as to maintain thesubstantially-circular and flat shape of the outer rim portion 1902. Theformation of the substrate 1802 in relation to the support ring 2000 canbe considered a first step in assembling, manufacturing, or fabricatingthe baffle 1800. Notwithstanding the above description, in which thesupport ring 2000 is a distinct component relative to the substrate 1802(and the outer rim portion 1902 thereof), in alternate embodiments amodified substrate can be employed in place of the substrate 1802. Insuch embodiments, the modified substrate can also include—in addition toflaps corresponding to the flaps 1804, living hinges corresponding tothe living hinges 1904, and an outer rim portion corresponding to theouter rim portion 1902—an additional ring structural portion thatcorresponds to the support ring 2000 and that is integrally formed withthe remainder of that modified substrate.

Turning to FIG. 21 and FIG. 22 , as already noted, the baffle 1800 notonly includes the subassembly 1900 including the substrate 1802, butalso includes the cylindrical gasket 1806, which constitutes an outerrim of the baffle 1800 for mounting in a strainer flange such as thestrainer flange 302 of FIG. 3 . In the present example embodiment, thecylindrical gasket 1806 is added to the subassembly 1900 by overmoldingthe substrate 1802 (and the support ring 2000 extending there within)with a thermoplastic elastomer (TPE) that forms the cylindrical gasket.The TPE-overmolded cylindrical gasket 1806, in addition to serving asthe outer rim of the baffle 1800, also hides and protects the livinghinges 1904 as is evident from FIG. 18 . It should be appreciated thatthis overmolding operation can be considered a second step in theassembling, manufacturing, or fabricating process of the baffle 1800.

As already mentioned, in the present example embodiment, the substrate1802 is formed from silicone and the cylindrical gasket 1806 is formedfrom TPE. Because TPE and silicone will not adhere to one another whenovermolding occurs, in the present embodiment mechanical interlocks areadditionally employed to join or attach the cylindrical gasket 1806 withthe subassembly 1900, including the substrate 1802. More particularly inthis regard, FIG. 21 shows a bottom perspective view of the baffle 1800that shows how the cylindrical gasket 1806 is interlocked with thesubassembly 1900, and FIG. 22 shows in more detail interlock features2200 that are formed on the cylindrical gasket 1806. Notwithstanding thepresence of the interlock features 2200, however, it should beappreciated that the baffle 1800 does not require any mechanicalassembly. Rather, the baffle 1800 is molded in a two shot process fromsilicone and TPE, and the mechanical interlocks between the molded partsare provided to facilitating maintenance of the final assembly formingthe baffle 1800 as an integrated unit.

As illustrated by FIG. 22 , the interlock features 2200 are multipleflanges that are arranged along an outer perimeter 2202 of a bottomannular surface 2204 of the cylindrical gasket 1806. The interlockfeatures 2200 particularly extend radially inward from the outerperimeter 2202 and then back (upward) toward the bottom annular surface2204 so as to establish several channels 2206 through which the supportring 2000 can pass when the cylindrical gasket 1806 is assembled to thesubassembly 1900. Further, as shown additionally by FIG. 21 , theinterlock features 2200 are spaced apart from one anothercircumferentially along the outer perimeter 2202 such that thecircumferentially-extending channel segments 2002 of the outer rimportion 1902 are circumferentially interleaved among the interlockfeatures 2200. Thus, with the cylindrical gasket 1806 formed by the TPEovermolding process, the tunnel-like interlock features 2200 are formedover the support ring 2000 between the circumferentially-extendingchannel segments 2002 of the outer rim portion 1902 that arecircumferentially-aligned with the living hinges 1904. Accordingly, asshown in FIG. 21 , a bottom annular outer perimeter surface 2100 of thebaffle 1800 includes multiple (in this case, eight) alternating pairs ofthe interlock features 2200 and the circumferentially-extending channelsegments 2002.

Referring additionally to FIG. 23 and FIG. 24 , the present disclosureis also intended to encompass a modified version of the additionalexample baffle 1800, which is shown in FIG. 23 as a further examplebaffle 2300. FIG. 23 particularly shows a bottom perspective view of thebaffle 2300 and FIG. 24 shows a bottom perspective view of a subassembly2400 of components of the baffle 2300. As with the baffle 1800, thebaffle 2300 includes a substrate 2302 with multiple flaps 2304 andadditionally a cylindrical gasket 2306. Also as was the case with thebaffle 1800, the baffle 2300 can form part of a food waste disposer(e.g., as described above in regard to the baffle 100 and the food wastedisposer 306), and can be implemented in regard to a strainer flange ofa sink (such as the strainer flange 302). In particular, as was the casewith the cylindrical gasket 1806 of the baffle 1800 described above, thecylindrical gasket 2306 is configured to allow for positioning of thebaffle 2300 within a strainer flange in a sink, in the same orsubstantially the same manner as is shown in FIG. 3 regardingimplementation of the baffle 100 in the strainer flange 302.

Turning particularly to FIG. 24 , the subassembly 2400 particularlyincludes the substrate (or substrate component) 2302 with the flaps2304, and additionally the substrate 2302 includes an outer rim portion2402 that surrounds all of the flaps 2304. Further, each of the flaps2304 is connected to the outer rim portion 2402 by way of a respectiveliving hinge 2404 extending outward from a respective radially-outwardportion 2406 of the respective flap. Also as is evident particularlyfrom FIG. 24 , the subassembly 2400 not only includes the substrate 2302with the flaps 2304, but also includes a support ring 2410. The outerrim portion 2402 of the substrate 2302, in addition to extendingentirely around all of the flaps 2304, also includes multiple (in thisexample, eight) circumferentially-extending channel segments 2412through which the support ring 2410 passes. By virtue of the supportring 2410 passing through the circumferentially-extending channelsegments 2412, the support ring is held in position relative to thesubstrate 2302 and therefore can provide support to the substrate so asto maintain the substantially-circular and flat shape of the outer rimportion 2402. Although in the present embodiment the support ring 2410can be a structure that is distinct from the substrate 2302, such thatthe subassembly 2400 includes the combination of both the substrate andthe support ring, in other embodiments (and as discussed further below)the support ring and substrate can be integrally formed together as onestructure.

As was the case with the living hinges 1904, each of the living hinges2404 is essentially a narrow neck portion of the same material out ofwhich each of the outer rim portion 2402 and the flaps 2304 are formed,and all of the outer rim portion 2402, the flaps 2304, and the livinghinges 2404 linking the flaps with the outer rim portion 2402 areintegrally formed as a single structure. Each of the living hinges 2404serves to allow the respective flap 2304 associated with that livinghinge to rotate upward and downward relative to the outer rim portion2402 in substantially the same manner as each of the flaps 104 canrotate relative to the annular manifold 102 of the baffle 100 describedabove (as was also the case with the living hinges 1904, in terms ofpermitting relative movement of the flaps 1804 and the outer rim portion1902). More particularly, each of the flaps 2304 can be rotated relativeto the outer rim portion 2402, as permitted by the respective one of theliving hinges 2404, above or below a horizontal or largely horizontal(or closed) position in which the respective flap 2304 extends generallyor substantially radially-inwardly toward a center of the outer rimportion 2402. Further, it can be said that each of the flaps 2304 is atleast indirectly supported in relation to the outer rim portion 2402 bythe respective living hinge 2404 in a rotatable manner such that each ofthe flaps can rotate about a respective additional axis that issubstantially tangent to a respective location along or proximate to therim portion (this can also be said about each of the flaps 1804 relativeto the outer rim portion 1902 by virtue of the respective living hinge1904). In addition to permitting such rotation of the flaps 2304, theliving hinges 2404 can also serve, during assembly or manufacture of thebaffle 2300, as runners in the molding process, so as to allow for themolding of the flaps 2304 and the outer rim portion 2402 as one part.

It will be appreciated that FIG. 23 and FIG. 24 respectively correspond,in terms of the views of the baffle 2300 and subassembly 2400 that areprovided, with the views of the baffle 1800 and subassembly 1900 thatare provided by FIG. 21 and FIG. 20 , respectively. At the same time,additional views of the baffle 2300, subassembly 2400, and gasket 2306corresponding to the views of the baffle 1800, subassembly 1900, andgasket 1806 that are provided by FIG. 18 , FIG. 19 , and FIG. 22 are notprovided. Rather, it should be understood that the particular viewsprovided by FIG. 23 and FIG. 24 illustrate certain features of thebaffle 2300 and subassembly 2400 thereof that differ to some extent fromthe features of the baffle 1800 and subassembly 1900 thereof, but thatotherwise when the baffle 2300, subassembly 2400, and gasket 2306 arerespectively viewed in the orientations/manners illustrated by FIG. 18 ,FIG. 19 , and FIG. 22 , the baffle 2300, subassembly 2400, and gasket2306 respectively appear identical to the baffle 1800, subassembly 1900,and gasket 1806 as illustrated by FIG. 18 , FIG. 19 , and FIG. 22 ,respectively. That is, in the present embodiments of the baffle 2300 andbaffle 1800 that are shown, all of the differences between the baffle2300 and the baffle 1800 are visible from a comparison of FIG. 23relative to FIG. 21 , and/or from a comparison of FIG. 24 relative toFIG. 20 .

Given the similarities between the baffle 2300 and the subassembly 2400thereof relative to the baffle 1800 and subassembly 1900 thereof, itshould be particularly appreciated from FIG. 23 and FIG. 24 that theflaps 2304 of the baffle 2300 can have features that are largelyidentical to those shown in FIG. 5 regarding the first one 400 of theflaps 104. In particular, each of the flaps 2304 includes a respectivetip portion 2314 that is elongated in the same manner as the tipportions 114. Also, as shown in FIGS. 23 and 24 , when the flaps 2304are all in the horizontal or largely-horizontal (or closed) positions,the tip portions 2314 of the flaps collectively define (or substantiallydefine) an inner orifice 2310 of the baffle 2300. Further, each of theflaps 2304 includes a respective main flat surface portion extendingfrom the respective radially-outward portion 2406 of the respective flaptoward the respective tip portion 2314 of the flap, as well as arespective curved transition region linking the respective main flatsurface portion with the respective tip portion. The main flat surfaceportions and curved transition regions of the flaps 2304 correspond tothe main flat surface portions 112 and curved transition regions 508 ofthe flaps 104 described above. Additionally, each of the flaps 2304 alsoincludes respective first and second side edges that are generallyrounded or curved and that respectively correspond to the first andsecond side edges 510, 512 described above in regards to the flaps 104of the baffle 100. Further, similar to the discussion above in regard tothe flaps 1804 of the baffle 1800, the flaps 2304 do also differ fromthe flaps 104 of the baffle 100 insofar as the flaps 2304 have theliving hinges 2404 extending from the radially-outward portions 2406 ofthe flaps rather than the extension portions 502 (or pair of integratedpins 506).

Notwithstanding the aforementioned similarities between the baffle 2300and subassembly 2400 thereof relative to the baffle 1800 and subassembly1900 thereof, there are certain differences between the baffle 2300 andsubassembly 2400 thereof relative to the baffle 1800 and subassembly1900 thereof. In particular, as is evident from each of FIG. 23 and FIG.24 , each of the flaps 2304 of the subassembly 2400 includes arespective pair of strengthening ribs 2408 that each extend along therespective underside of the respective flap, substantially the entireextent of the respective main flat surface portion of the respectiveflap between the respective radially-outward portion 2406 (or respectiveliving hinge 2404 at that respective radially-outward portion) and therespective tip portion 2314 of the respective flap. In the presentexample embodiment, each of the respective ribs 2408 of the respectivepair of ribs of each respective flap 2304 has a diameter, as measuredperpendicular to the elongated length dimension of the respective rib,which is less than half of the width of the respective tip portion 2314of the respective flap 2304. Also in the present embodiment, each of therespective ribs 2408 formed on each respective one of the flaps 2304particularly runs along and proximate to a respective side edge of therespective flap, that is, along and proximate to a respective edge ofthe respective flap that corresponds to either one of the first sideedges 510 or one of the second side edges 512 discussed above in regardto the flaps 104 of the baffle 100. In this regard, each of therespective ribs 2408 can be spaced slightly toward the interior of therespective flap 2304, apart from the respective side edge of therespective flap, by a small distance (e.g., a distance that issubstantially equal to or less than the width of the respective rib).

It should be noted that experimental testing has demonstrated that theinclusion of the strengthening ribs 2408 particularly can enhance thestrength of the flaps 2304 from the standpoint of limiting or reducingthe extent to which the flaps 2304 tend to move vertically upward (ordownward, from the standpoint of the baffle 2300 when viewed upside-downas shown in FIG. 23 ) due to forces imparted upon the undersides of theflaps, e.g., as might occur during operation of a food waste disposerpositioned beneath the flaps 2304 such as discussed in relation to FIG.3 . Indeed, according to some tests, due to the presence of a pair ofthe ribs 2408 along a given one of the flaps 2304, more (e.g., 3.4%more) or substantially more (e.g., 41.7% more) force is required to movethe flap 2304 upward to a particular degree than would be required tomove a substantially similar flap lacking such ribs upward to the samedegree.

In the present example embodiment, the substrate 2302 in its entirety,including the outer rim portion 2402, the flaps 2304, and the livinghinges 2404, can be made using silicone, which provides a tactilerubbery feel to the flaps 2304 and provides an appropriate level ofrobustness for the living hinges 2404. The formation of the substrate2302 in relation to the support ring 2410 can be considered a first stepin assembling, manufacturing, or fabricating the baffle 2300.Notwithstanding the above description, in which the support ring 2410 isa distinct component relative to the substrate 2302 (including the outerrim portion 2402, flaps 2304, and living hinges 2404 thereof), in otherembodiments and as discussed further below, a modified substrate can beemployed in place of the substrate 2302. In such embodiments, themodified substrate can also include in addition to flaps correspondingto the flaps 2304, living hinges corresponding to the living hinges2304, and an outer rim portion corresponding to the outer rim portion2402 an additional ring structural portion that corresponds to thesupport ring 2410 and that is integrally formed with the remainder ofthat modified substrate.

As already mentioned above, the baffle 2300 not only includes thesubassembly 2400 including the substrate 2302, but also includes thecylindrical gasket 2306, which constitutes an outer rim of the baffle2300 for mounting in a strainer flange such as the strainer flange 302of FIG. 3 . In the present example embodiment, the cylindrical gasket2306 is added to the subassembly 2400 by overmolding the substrate 2302(and the support ring 2410 extending therewithin) with a thermoplasticelastomer (TPE) that forms the cylindrical gasket. The TPE-overmoldedcylindrical gasket 2306, in addition to serving as the outer rim of thebaffle 2300, also hides and protects the living hinges 2304 (in the samemanner as discussed above with respect to FIG. 18 ). In otherembodiments, as discussed below, different materials other than TPE canbe employed to perform the overmolding and to form the cylindricalgasket 2306 including, for example, urethane. It should be appreciatedthat this overmolding operation can be considered a second step in theassembling, manufacturing, or fabricating process of the baffle 2300.

As already mentioned, in the present example embodiment, the substrate2302 is formed from silicone and the cylindrical gasket 2306 is formedfrom TPE. Because TPE and silicone will not adhere to one another whenovermolding occurs, in the present embodiment mechanical interlocks areadditionally employed to join or attach the cylindrical gasket 2306 withthe subassembly 2400, including the substrate 2302. The bottomperspective view of the baffle 2300 particularly shows that thecylindrical gasket 2306 is interlocked with the subassembly 2400 againby way of interlock features 2420 that are formed on the cylindricalgasket 2306, spaced around an outer perimeter 2422 of that gasket.Notwithstanding the presence of the interlock features 2420, however, itshould be appreciated that the baffle 2300 does not require anymechanical assembly. Rather, the baffle 2300 is molded in a two shotprocess from silicone and TPE, and the mechanical interlocks between themolded parts are provided to facilitating maintenance of the finalassembly forming the baffle 2300 as an integrated unit.

As discussed above, FIG. 22 not only shows the cylindrical gasket 1806but also is representative of the cylindrical gasket 2306 that engagesthe subassembly 2400 to form the baffle 2300. In this regard, it shouldbe appreciated that the interlock features 2420 of the cylindricalgasket 2306 (which are shown in FIG. 23 ) take the same form as theinterlock features 2200 shown in FIG. 22 . That is, the interlockfeatures 2420 take the form of multiple flanges that are arranged alongthe outer perimeter 2422 of the cylindrical gasket 2306, particularlyaround a bottom annular surface (corresponding to the bottom annularsurface 2204) of the cylindrical gasket 2306. The interlock features2420 extend radially inward from the outer perimeter 2422 and then back(upward) toward the bottom annular surface so as to establish severalchannels (corresponding to the channels 2206) through which the supportring 2410 can pass when the cylindrical gasket 2306 is assembled to thesubassembly 2400. Further, as shown by FIG. 23 , the interlock features2420 are spaced apart from one another circumferentially along the outerperimeter 2422 such that the circumferentially-extending channelsegments 2412 of the outer rim portion 2402 are circumferentiallyinterleaved among the interlock features 2420. Thus, with thecylindrical gasket 2306 formed by the TPE overmolding process, thetunnel-like interlock features 2420 are formed over the support ring2410 between the circumferentially-extending channel segments 2412 ofthe outer rim portion 2402 that are circumferentially-aligned with theliving hinges 2404. Accordingly, as shown in FIG. 23 , a bottom annularouter perimeter surface of the baffle 2300 (corresponding to the surface2100 of FIG. 21 ) includes multiple (in this case, eight) alternatingpairs of the interlock features 2420 and the circumferentially-extendingchannel segments 2412.

As mentioned above, although in some embodiments the support ring 2410and substrate 2302 are separate, distinct structures that together formthe subassembly 2400, in other embodiments the subassembly 2400 caninstead be a flap ring structure having features that include both thefeatures of the substrate 2302 (including the flaps 2304, outer rimportion 2402, and living hinges 2420) as well as the features of thesupport ring 2410. In such embodiments, the support ring 2410 andsubstrate 2302 can be considered to be integrally formed with oneanother. In at least some such embodiments, such a flap ring structure(or simply flap ring) with its multiple interconnected flaps willtypically be the first part to be molded. Further, the flap ring in somesuch embodiments can be made from a material having excellent creepresistance at elevated temperatures, so as to prevent the flaps fromsagging over time with exposure to hot water. Additionally, a materialproviding tear resistance is also desirable, to prevent torn flaps. Onematerial that can satisfy these objectives can be, for example, cast RTV(room-temperature-vulcanizing) silicone, with Shore A Hardness ofapproximately 40, can be employed. Such a silicone material can exhibitexcellent chemical, heat, and tear resistance. Additionally, forproduction it can be appropriate to employ injection molding grades ofsilicone.

Regardless of whether the support ring 2410 and the substrate 2302 areseparate, distinct structures that form the subassembly 2400 or insteadare integrally formed with one another as a flap ring, the cylindricalgasket 2306 can in each case serve several purposes. In particular, thecylindrical gasket 2306 can serve to retain the overall baffle assembly(e.g., the baffle assembly 2300) within a sink drain, as well as serveto house the subassembly 2400/flap ring, and further particularly serveto shield the living hinges 2404 of the subassembly 2400/flap ring fromobjects falling into the sink/drain. The cylindrical gasket 2306particularly can be molded over the subassembly 2400/flap ring and formmechanical interlocks around the ring as illustrated by FIG. 22 and FIG.23 . So as to allow the flaps 2304 of the subassembly 2400/flap ring tofreely rotate about hinge points provided by the living hinges 2404, thecylindrical gasket 2306 can be made of a material that does notchemically bond to the material forming the subassembly 2400/flap ring.Such a material can for example be a cast urethane was utilized with aShore A Hardness of approximately 60, particularly insofar as urethanedoes not chemically bond to silicone and offers good chemical resistanceto common chemicals used in sinks. Also, injection molded thermoplasticelastomers may be used in production. Regardless of what particularmaterials are employed, the materials are chosen such that, when thegasket is overmolded onto the flap ring, the gasket material does notbond (chemically or otherwise) with the flap ring, which allows theflaps to be able to move.

It should be further appreciated that, during themaking/manufacture/assembly of the baffle 2300, regardless of whetherthe support ring 2410 and the substrate 2302 are separate, distinctstructure or integrally formed with one another, the order of moldingsteps that are performed should be consistent with the materials thatare used for the different components. For example, manufacturing of anembodiment of the baffle 2300 having the flap ring in which the supportring and substrate are integrally formed with one another, typicallywill involve a first molding step in which the flap ring is formed froma first material, followed by a second molding step in which thecylindrical baffle 2306 is formed from a second material that is moldedaround the flap ring. In such a process, the first material meltingtemperature associated with the first molding step (forming the “firstshot”) typically will be higher than that of the subsequent shot(s)(e.g., the second material melting temperature associated with thesecond molding step), so that the first shot does not melt or deformwhen the second material is injected. The materials mentioned above—andespecially silicone being employed as the first shot material used forthe flap ring—satisfy these goals. Indeed, silicone has a very high melttemperature and allows for a large range of melt temperatures whenselecting the second shot material (whether urethane or anothermaterial).

Further in regard to the baffle 2300 of FIG. 23 described above, FIG. 25and FIG. 26 are additionally provided to show perspective views ofcutaway portions of cross-sections of that baffle. FIG. 25 particularlyshows a perspective view of one cutaway portion of one cross-section ofthe baffle 2300. The particular view of FIG. 25 illustrates the baffle2300 when it is in a non-inverted position, that is, a position typicalof normal implementation in relation to a sink and waste disposer (e.g.,according to which material proceeds downward from the sink drain,through the baffle, and into the waste disposer). It should beappreciated that, although FIG. 25 is intended to show a cross-sectionof a portion of the baffle 2300, the one of the flaps 2304 of thesubstrate 2302 that is shown is in a somewhat depressed positionrelative to the flaps 2304 shown in FIG. 23 , as if that one flap wasbeing pushed downward (e.g., as would often be the case in circumstancesin which material is passing downward through the baffle 2300 from asink into a disposer). Such a depressed position would correspond topositioning of any of the flaps 2304 upwardly by comparison with thepositioning of the flaps shown in FIG. 23 , because the baffle 2300 isshown in an inverted position (relative to how the baffle wouldtypically be positioned in relation to a sink and waste disposer).

FIG. 26 is an additional perspective view of an additional cutawayportion of an additional cross-section of the baffle 2300 of FIG. 23 ,taken when that baffle is in an inverted position (e.g., consistent withthe position of the baffle as shown in FIG. 23 ). In contrast to FIG. 25, the one of the flaps 2304 of the substrate 2302 that is shown in FIG.26 is in a somewhat elevated position relative to the flaps 2304 shownin FIG. 23 , as if that one flap was being pushed upward (e.g., due toan air bubble within the waste disposer or as could occur duringoperation of a waste disposer if material within the waste disposer wasdriven upward). Such an elevated position would correspond topositioning of any of the flaps 2304 downwardly by comparison with thepositioning of the flaps shown in FIG. 2 , again because the baffle 2300is shown in an inverted position (relative to how the baffle wouldtypically be positioned in relation to a sink and waste disposer). Forpurposes of the description provided below, it can be assumed that theone of the flaps 2304 that is shown in FIG. 25 is also the same one ofthe flaps 2304 that is shown in FIG. 26 .

FIG. 25 and FIG. 26 each show not only one of the flaps 2304 of thesubstrate 2302 of the baffle 2300, and a portion of the cylindricalgasket 2306 of the baffle 2300, but also illustrate additional aspectsof the baffle 2300 as well. In particular, FIG. 26 shows the pair ofstrengthening ribs 2408 that are present along the underside surface ofthe one of the flaps 2304 that is shown, and that extend substantiallythe entire distance between the tip portion 2314 of that flap and theone of the living hinges 2404 coupling that flap with a correspondingone of the circumferentially-extending channel segments 2412 (of theouter rim portion 2402 of the substrate 2302). Additionally, FIG. 25further illustrates how the cylindrical gasket 2306 extends radiallyinwardly from the location of the support ring 2410, so as to extend to(or even past) the radially-outward portion 2406 of the one of the flaps2304 that is shown, such that the cylindrical gasket 2306 covers over(and protects) the one of the living hinges 2404 (not shown) thatcouples that flap to the outer rim portion 2402 (not shown). Further,not only does each of FIG. 25 and FIG. 26 show a respectivecross-section that illustrates how the cylindrical gasket 2306 isovermolded (and molded around) the support ring 2410, but also FIG. 26in particularly illustrates a junction 2424 between the cylindricalgasket 2306 and the substrate 2302. In particular, it will beappreciated from FIG. 26 that the junction 2424 exists between the oneof the circumferentially-extending channel segments 2412 that is shownin FIG. 26 and adjacent ones of the interlocking features 2420 alsoshown in FIG. 26 . Additionally, FIG. 26 shows how the junction 2424exists between the cylindrical gasket 2306 and the one of the flaps 2304shown therein (particularly along the radially-outward portion 2406 ofthat flap), particularly when that flap is in the elevated positionshown in FIG. 26 .

It should be appreciated that the cylindrical gasket 2306 of the baffle2300, by way of contact with the flaps 2304 at locations such as (forexample) the junction 2424, can provide forces in relation to the flapsthat tend to cause the respective flaps to remain at their respectiveclosed positions (e.g., horizontal or largely-horizontal positions) whenalready at the respective closed positions, or to return to theirrespective closed positions when not at the respective closed positions.In some embodiments, such forces provided by the cylindrical gasket 2306are entirely or substantially responsible for retaining the flaps 2304at, and/or returning the flaps to, the respective closed positions,although in other embodiments the flaps 2304 are retained at, orreturned to, their closed positions due to spring forces provided by theliving hinges 2404, or by a combination of the forces provided by theliving hinges and the cylindrical gasket. In such manners, the flaps2304 can be retained at, or returned to, their closed positions withoutthe use of an elastic band such as any of the elastic bands (e.g., theelastic bands 108, 1508) described above. Similarly, it should beappreciated that the flaps 1804 of the baffle 1800 also can be retainedat, or returned to, their closed positions by way of forces applied bythe cylindrical gasket 1806 relative to the flaps, or due to springforces provided by the living hinges 1904, or by a combination of suchdifferent types of forces.

Although differing in some respects from the baffle 100 described above,the baffles 1800 and 2300 may achieve one or more advantages that areidentical or substantially similar to one or more of those describedabove in regard to the baffle 100. For example, in at least some cases,each of the baffles 1800 and 2300 can fit into a strainer flange such asthe strainer flange 302 of FIG. 3 and would be removable from a sinkopening to leave the full drain opening accessible to a user. Also, forexample, given the shape of the flaps 1804 that include the elongatedtip portions 1814 of the baffle 1800, or the shape of the flaps 2304that include the elongated tip portions 2314 of the baffle 2300, in somecases it may be easier for a user to remove the user's hand or fingerseither of the baffles 1800 or 2300 (after being inserted into either ofthe baffles) and away from a food waste disposer (and thus avoidfinger-trapping) than is the case with one or more conventional baffles.

Further, although neither of the baffles 1800 and 2300 in the presentembodiment includes-any elastic band corresponding to the elastic band108, nevertheless, each of the baffles 1800 and 2300 can be consideredan active baffle design. The living hinges 1904 that couple the flaps1804 with the outer rim portion 1902 in the baffle 1800, and the livinghinges 2404 that couple the flaps 2304 with the outer rim portion 2402in the baffle 2300, particularly allow for force to be exerted upon therespective flaps tending to cause those respective flaps to remain at,or to return to, horizontal or largely-horizontal (or closed) positionssuch as those shown in FIG. 18 , FIG. 21 , and FIG. 23 . At the sametime, in alternate embodiments, elastic bands can be additionallyprovided that extend around the flaps and that further cause the flapsto remain at, or to return to, the horizontal or largely-horizontal (orclosed) positions.

As active baffle designs, each of the baffles 1800 and 2300 also mayprovide any of a variety of further advantages (e.g., in addition to orinstead of any of those mentioned above) by comparison with one or moreconventional passive baffle designs including, further for example,enhanced sound reduction, increased ease of food waste insertion, andimproved, appropriate, water draining (e.g., so as to avoid waterback-up into the drain opening that may create the perception of aclogged sink) regardless of the water flow characteristics of theinstallation.

Further, although it is possible for all of the flaps 1804 of the baffle1800 to move in unison, as well as possible for all of the flaps 2304 ofthe baffle 2300 to move in unison, it is also possible for any of theflaps of either of those baffles to move individually, or for two ormore of the flaps to move while one or more others of the flaps do notmove, or for different one(s) of the flaps to move to different degreesthan other one(s) of the flaps of that baffle. This is to be contrastedwith one or more conventional pleated baffle designs in which, asdiscussed above, the pleats of the baffle all are interconnected andmove together, such that the combined stiffness of all of the pleats maybe too high for the pleats to be displaced and allow water to flowthrough the baffle properly under certain water flow conditions. Thatis, each of the baffles 1800 or 2300 may operate in a manner such that,in some operational circumstances, only a subset of the flaps 1804 or2304 of the respective baffle is or are displaced in response to waterflow, thereby facilitating the water flow.

Although several example embodiments of baffles have been describedabove, the present disclosure is intended to encompass numerous otherembodiments as well. For example, although several of the embodiments ofbaffles described above employ elastic bands while others do not, thepresent disclosure is intended to encompass other embodiments thatdiffer from one or another of those described above in terms of thepresence or absence of an elastic band, as well as other embodiments inwhich there are multiple elastic bands instead of only a single elasticband. For example, the present disclosure is intended to encompassembodiments of baffles having flaps and living hinges in combinationwith elastic bands, where the elastic bands (by themselves, or incombination with the living hinges, or possibly additionally incombination with gaskets such as the cylindrical gaskets 1806 or 2306)serve to cause the flaps to be retained in, or to return to, theirclosed positions. Further, the present disclosure is intended toencompass embodiments in which the baffles, or component parts thereof,are made of other materials than those described above. Also, althoughthe above-described embodiments of baffles have flaps that aresubstantially sector-shaped, with the flaps of each given baffle beingidentical or substantially identical with one another, in otherembodiments the flaps can take on different shapes and, indeed, in someother embodiments different ones of the flaps of a given baffle can havedifferent shapes. Additionally, although the baffles described above areannular or substantially annular in cross-section, the presentdisclosure is also intended to encompass other baffle designs that haveother shapes.

Further, although some rim portions described above such as the outerrim portions 1902 and 2402 are shown as fully circumferentiallyextending fully around the central axis of the baffle (and extending soas to surround all of the flaps of a baffle in a continuous manner), thepresent disclosure is also intended to encompass embodiments in whichsuch rim portions only extend partly around the central axis of thebaffle. For example, in some such embodiments, an outer rim portion canhave a circumferential extent limited to that provided by thecircumferentially-extending channel segments 2002 or 2412 of the baffles1800 or 2300, respectively. In some such embodiments, further structuralrigidity of the respective baffle (and particularly of the substratethereof) can be provided by the inclusion of a support ring such aseither of the support rings 2000 or 2410 to link the various ones of thecircumferentially-extending channel segments. Such embodiments can stillbe considered embodiments in which the outer rim portion, with acircumferential extent limited to that provided by thecircumferentially-extending channel segments, extends substantiallycircumferentially around a central axis of the baffle. Further,notwithstanding the description above concerning certain connectingfeatures such as integrated pins that fit within slots, in otherembodiments other connecting features can be employed, includingfeatures that are the inverse of those described above (e.g.,embodiments in which pins formed on an annular manifold fit within slotsformed on flaps).

In addition, notwithstanding any description above concerning manners ofassembling, manufacturing, fabricating, or operating any baffles orrelated or associated structures, the present disclosure is intended toencompass additional manners of assembling, manufacturing, fabricating,or operating any baffles or related or associated structures, includingones in which various procedural steps have been added, changed, oromitted relative to anything described above. Additionally,notwithstanding the usage of terms describing directional orientationsof baffles, component parts, or other structures herein, relative toground or otherwise, such as downward, upward, bottom, or top, thepresent disclosure is intended to encompass embodiments in which suchbaffles, components parts, or other structures have other orientations,and the present disclosure is not intended to be limited to anyparticular orientations described herein. Further, numerical rangesprovided herein are understood to be exemplary and should be understoodto include all possible numerical ranges situated there between.

Further, in least some example embodiments, the present disclosurerelates to a baffle for implementation in connection with a food wastedisposer. The baffle includes a rim portion substantiallycircumferentially extending around a central axis of the baffle, and aplurality of flaps at least indirectly supported by the rim portion,where each of the flaps is substantially sector-shaped. The baffle alsoincludes an annular portion connected or integrally formed with the rimportion, where the annular portion includes an outer surface configuredto facilitate mounting of the baffle in relation to an externalstructure. Each of the flaps is at least indirectly supported inrelation to the rim portion in a rotatable manner such that each of theflaps can rotate about a respective additional axis that issubstantially tangent to a respective location along or proximate to therim portion. Also, each of the flaps can be rotated so as to attain arespective closed position in which the respective flap extends radiallyinwardly, from a respective radially-outward portion of the flappositioned proximate to the respective location to a respective tipportion of the flap. Additionally, when each of the flaps isrespectively rotated so as to attain the respective closed position, therespective tip portions of the respective flaps collectivelysubstantially define an inner orifice of the baffle through which thecentral axis passes. Further, the baffle includes one or more componentsthat tend to cause the respective flaps to remain at the respectiveclosed positions when already at the respective closed positions, andthat tend to cause the respective flaps to return to the respectiveclosed positions when not at the respective closed positions.

Additionally, in at least some such embodiments, each of the flapsincludes a respective first coupling formation, at or proximate to therespective radially-outward portion of the respective flap, which isconfigured to interface with a respective second coupling formation onthe rim portion, and the respective axes about which the respectiveflaps can rotate are defined by the first or second coupling formations.Further, in at least some such embodiments, the respective firstcoupling formation includes a respective pin, the second couplingformation includes a respective slot, and each of the respective flapsis attached to the rim portion by way of the respective pin beingpositioned within the respective slot. Additionally, in at least somesuch embodiments, the one or more components include a plurality oftorsion springs that are respectively positioned so as to extend aroundthe respective pins. Further, in least some such embodiments, the rimportion is integrally formed with respect to the annular portion, theone or more components include a plurality of finger extensions of therim portion, and the respective finger extensions respectively extendinto respective receiving orifices within the respective flaps.

Further, in at least some example embodiments encompassed herein, thepresent disclosure relates to a baffle for implementation in connectionwith a food waste disposer. The baffle includes a rim portionsubstantially circumferentially extending around a central axis of thebaffle, a plurality of flaps, and a plurality of living hinges, wherethe respective living hinges respectively link the respective flaps tothe rim portion such that the rim portion, living hinges, and flapsconstitute a single integrally-formed structure. The respective livinghinges permit the respective flaps to be rotatable about respective axesthat respectively are substantially tangent to respective locationsalong or proximate to the rim portion, so that the respective flaps canbe rotated to respective closed positions. Further, either the livinghinges or at least one additional component tend to cause the respectiveflaps to remain at the respective closed positions or to return to therespective closed positions when not at the respective closed positions.

Additionally, in at least some example embodiments encompassed herein,the present disclosure relates to a method of assembling a baffle thatis for implementation in connection with a food waste disposer. Themethod includes providing a primary structure having a first structuralportion and a ring structural portion, where the first structuralportion includes a rim portion substantially circumferentially extendingaround a central axis of the baffle, a plurality of flaps, and aplurality of living hinges that together constitute a singleintegrally-formed structure that is formed from a first material, andwhere the ring structural portion is connected with or integrally formedwith the first structural portion. The method further includesovermolding a secondary structure on the primary structure, where thesecondary structure is formed from a second material, and where thesecondary structure includes a plurality of interlocking features thatfacilitate coupling of the secondary structure in relation to theprimary structure. Either the living hinges or at least one additionalcomponent tend to cause the respective flaps to remain at the respectiveclosed positions or to return to the respective closed positions whennot at the respective closed positions.

It is specifically intended that the present invention not be limited tothe embodiments and illustrations contained herein, but include modifiedforms of those embodiments including portions of the embodiments andcombinations of elements of different embodiments as come within thescope of the following claims.

1-19. (canceled)
 20. A method of assembling a baffle that is forimplementation in connection with a food waste disposer, the methodcomprising: providing a primary structure having a first structuralportion and a ring structural portion, wherein the first structuralportion includes a rim portion circumferentially extending around acentral axis of the baffle, a plurality of flaps, and a plurality ofliving hinges that together constitute a single integrally-formedsilicone structure, and wherein the ring structural portion is connectedwith or integrally formed with the first structural portion; andovermolding a secondary structure on the primary structure, wherein thesecondary structure is formed from a thermoplastic elastomer (TPE)material, and wherein the secondary structure includes a plurality ofinterlocking features that facilitate coupling of the secondarystructure in relation to the primary structure; wherein either theliving hinges or at least one additional component tend to cause therespective flaps to remain at the respective closed positions or toreturn to the respective closed positions when not at the respectiveclosed positions.